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If you slide the bed up and down by hand, does the z-switch engage and disengage properly, clicking on and off? If you 'lower the bed' using the front panel controller, does it hit the limit switch, bounce off, and then resettle - all without making nasty noises?

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Now you tell us? That's definitely the problem. It needs to hit the limit switch. There is a long screw at the bottom of the bed that goes up and down when the bed goes up and down. That long screw needs to hit the Z limit switch when it does it's homing procedure. You can hear the switch click if it is working. The switch could be loose or might need slight adjustment.

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Homing isn't done very often. Typically it's the first thing done when starting a print.

By the way, how do you slide the bed by hand?

The first time you try it, do it with power off. Just push down firmly with your hands as close to the rear of the platform as possible. Same with lifting, lift near the rear. Just push and pull hard enough until it starts moving.

Then later you can try it with power on. If the servo is powered (often it is not!) then the bed won't move.

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I'm worried that sometimes the build plate isn't triggering the Z limit switch, but sometimes it does. I'm worried that if the build plate moves .1mm farther it hits something. Ideally you want the bed to go down enough until you hear the "click" from the switch, and then can move another mm (minimum) before hitting something that stops the bed from going farther.

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If you push it by hand, you can certainly push it further than the point at which the switch triggers. But when starting up in this position, the printer should realize that the switch is triggered, and move upwards only. Hmm. I wonder if it's possible to push the bed down further than the 'back-off/bounce' distance so that it never untriggers itself before the re-trigger...

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No, on mine... If I do 'lower buildplate', then turn power off and push bed all the way down, then turn it on, and do lower buildplate, it seems like it just moves up until the switch unclicks and then stops. Which seems like reasonable behavior.

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I have to pay attention at that click sound as it isn't very clear to me how it should sound like.

With power off, raise the bed.

Now take a toothpick or something small and push it through that hole under the bed and listen for the click when you push on the endstop. Note the screw sticking out under the bed that goes into that hole.

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